Sewing Line Layout
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Transcript of Sewing Line Layout
NATIONAL INSTITUTE OF FASHION TECHNOLOGY, GANDHINAGAR
PLANT LAYOUT
Submitted to: Submitted by:
Mr.Manoj Tiwari Aryan Singh
Ruchika Tripathi
Swati Singh
DFT- 7
Plant layout is the spatial arrangement and configuration of departments, work
stations, machinery and equipment used in the conversion process. Layout of
an apparel production plant directs the flow of materials and work-in-process
from start till its completion and integrates material handling and equipment.
An efficient layout has the flexibility to be changed to meet requirements of
the product line, delivery schedules, and anticipated volume. Safety is a major
consideration in plant layout. Fire and safety codes, emergency and accessible
exits, open traffic areas, etc. must all be a part of layout plans.
The following factors should be taken into consideration while planning a
layout:
Minimization of manufacturing costs
Efficient work flow
Minimization of work transfer
Provision of future expansion
Selection of Factory Site
Demographic, Infrastructural, Natural and Social factors should be
considered before selecting a location for a factory site.
Demographic and Infrastructural analysis is all about understanding
population age groups, per capita income, education level, occupational
structure and availability of skilled and non skilled manpower, technically
qualified and trained supervisors and managers, transportation cost, link
roads, nearness to railway station, airport or sea port, banking and financial
institutes..
Natural and social factors like climatic conditions, pollution, public hazards,
political problems, local laws and regulations, medical services, public
utilities, civic amenities and means of communication should also be
analysed before selection of the layout.
Layout of the Plant
Layout of the plant is decided based on process sequence, building
structure, shop floor transportation, type of layout (product or process
based or a combination of both) and arrangement of machines. The aim of
every layout is to maximize utilization of available space in order to speed
up the material flow. Highly specialized machines and small parts assembly
may be configured with a line arrangement for final assembly.
Factors to be considered for designing an effective layout include number
of workers both male and female, number of machines (size, weight by
models), entrance, exit and passages (size, width, position, number of each
of them) for production as well as administrative wing, change room, lunch
room, lavatories, medical emergency room and provision for those
governed by local laws. Utilities like boiler, air compressor, vacuum pumps,
generator, electric panel, air conditioning machine, underground water
storage tanks for boiler and washing machines, water softening plant,
waste water recycling plant, drainage system are also equally important.
Other factors that need attention before laying out the factory plan include
ceiling height (3-3.5 metres from floor), lighting (large windows of 2 or 3
stages) and illuminance levels (600 Lux for production and 800 Lux for
inspection areas) besides ventilation. Also, the workplace should have
sufficient number of men’s and women’s toilets and drinking water outlets
in the vicinity.
Objective: To set up a manufacturing unit producing 3500 women’s semi
formal shirt per day
Plot Area: (22*100) 2200 sq m
FSI – 1.2
Ground Coverage: 80%
Total area that can be constructed = 2200 * .80 = 1760 sq m
Specifications of the style studied
Raw Material Specification Consumption/garment
Body Fabric Poplin 1.81 m
Interlining Microdot 0.42 m
Button Plastic (14 L) 16 pcs
Thread (Ticket No.
25)
Spun Polyester 35 m
Thread (Ticket No.
50)
Spun Polyester 38 m
Thread (Ticket No.
100)
Spun Polyester 195 m
Paper Printed tag - 1 pc
Printed Paper 1 pc
Main Label 1 pc
Wash Care Label 1 pc
Stores
Receipt of Bill Of Materials
Package verification against packing list for weight & no of packages
Materials received
Lab test Trim card for accessories
No
To be inspected
Rejected Inspection process Yes pass
Quality checking
Storage of passed material
Update status to production
Issues of fabric to cutting section based on lay
record
Issues of trims to production
Receipt of end bits from cutting section
Receipt of left over materials from production
Inspection fail
Conditionally approved by buyer
Rejected
Storage in rejected Area
STORES DEPARTMENT
Process flow chart :
In stores department we have to keep an inventory of 15 days for the required
raw material.
Therefore we have to plan the no. of racks required and their dimensions.
Racks for Accessories:
All the accessories will be kept in a box.
Here we have assumed the dimension of the box and approximately the no. of
pcs that can be accommodated in the box.
Accessories Required
Amount
for 15
days
Dimensio
n of box
(inches)
l*b*h
No. of pcs that
can be
accommodated
Volume
of box(in
cubic
inch)
Required
volume
(in cubic
inch)
Button 840000 3*2.5*2 2000 15 6360
Thread(Tk
No. 25)
1837500 8*8*2.5 30000 160 9800
Thread(Tk
No. 50)
1995000 8*8*2.5 30000 160 10640
Thread(Tk
No. 100)
10237500 8*8*2.5 30000 160 54600
Printed
Paper Tag
52550 4*3*2 100 24 12612
Printed
Paper
52550 16*16*1 200 256 67264
Main Label 52550 5 Dia*2 375 157 22000
Wash Care
Label
52550 5 Dia*2 375 157 22000
Therefore total required volume (in cubic inch)
205276
Dimension of racks for accessories = 34*21*66(inches) or 0.86*0.53*1.6
meters
Total Volume required (in cubic inch) = 205276
Therefore 4 racks will be required.
Racks for body fabric and interlining
Fabric Interlining
Required length for 15
days (m)
95025 22050
Length in a roll (m) 300 100
No. of rolls req. 317 220
Diameter of roll (inch) 12 6
Length of roll (inch) 64 40
No. of rolls in one
shelf(assumed)
7 10
Length of the rack(as per
given rolls/shelf) (inch)
84 60
Ease of roll movement
lengthwise (inch)
5 5
Final Length of
shelf(inch)
89 65
Ease of roll movement
heigthwise (inch)
6 6
Distance b/w two
successive shelfs (inch)
18 12
Required no. of shelves 45 22
Height of the rack(inch) 90 75
No. of shelves in one
rack
5 6
Width of the rack 69 45
Dimension of the
rack(inches)
89*69*90 65*45*75
Dimension of the
rack(meters)
2.26*1.75*2.28 1.65*1.14*1.90
No. of racks required 9 4
There will be two fabric inspection machines in stores department of
dimension 2.43*1.82 meters
CUTTING DEPARTMENT
Receive fabrics from stores
Sample cutting
Approval of sample cutting
Receipt of cut file & pattern ( CAD Process)
Plan for cutting based on basic cutting plan & fabric allocation
Release lay record
Receipt of fabric
Laying & spreading Marker inspection
Lay inspection
Cut parts inspection
Numbering
Panel checking
Re cutting
Embroidery / printing / fusing
Fusing inspection
Sorting
Storage
Issue to sewing
Dimension for cutting room furniture
Length=Marker length + allowance for fabric rolls
We have taken marker length (4 way marker) = 7.15m
Allowance = 1.5 m
Total length = 8.65 m
Width =Width +Allowance
Width=1.52 m
Allowance=0.3 m
Total width =1.82m
Dimension of cutting table for fabric =8.65*1.82*0.84 meters
No. of tables required
Total no. of minutes=480
Width(m) 1.52
Components of garments 28
Cut capacity/day 3500
Marker Length(m) 7.15
No. of garments in a
marker
4
Av. Fabric
consumption(m)
1.81
No. of plies in lay 135
No. of lays 7
Av. Time for laying
/lay(mins)
140
Av. Time for cutting
/lay(mins)
100
Total time for cutting &
laying (mins)
240
Total no. of tables for
laying & cutting
4
Av. Tim for sorting 1
garment/person(min)
1
Av. Time for sorting 500
garments(min)
500
Sorting and bundling
tables
2
No. of fusing machines
(3.3 x 1.6 mt)
2
Band knife machine s 1
(2.25 x 1.5)
Fusing assisting tables 2
Trolleys
In cutting dept. there will be fabric temporary storage.
Calculation of Fabric Temporary Storage
Fabric
Cutting days inventory 1.5
Required fabric
length(m)
9502
Length in a roll (m) 300
No. of rolls req. 31
Diameter of roll (inch) 12
Length of roll (inch) 64
No. of rolls in one
shelf(assumed)
2
No. of rolls in a rack 15
No. of racks 2
Ease for roll
movement(inches)
6
Length of rack(inches) 66
Therefore the dimensions of the rack = 66*60*42 inches or 1.32*1.2*0.84
meters
SEWING DEPARTMENT
Receipt of cut parts from cutting section
Receipt of machine layout
Study of layout & set the batch
Load pilot run lot
Approval of pilot run
Load bulk cutting
Monitor production as per target
End line checking
Total SAM = 23.27 minutes
Total operations (including ironing, marking) = 48
Total time available = 480 minutes
Total pieces required = 3500
Pieces per minute = 3500/480
= 7.30 pieces
Operation breakdown and line balancing has been done keeping in mind the
pieces required and the SAM of the individual operations. Accordingly, number
of machines required for each operation has been found out.
Line Layout:
The layout that has been chosen for the line is the most common method of
arranging machines with centre table option; here all operators are facing in
one direction. For one column of workers the centre table is on left, while for
the other column of operators the centre table is on right, hence differential
ease of bundle pickup and disposal. Centre table on the left side of the
operator is always better for larger component. For operations involving a two
component assembly where picking has to be done from both right and left of
the operators, the service table at right is advisable, this is because additional
extension space can be created at left side with comparative ease but creating
additional space at right side of machine is difficult. Generally wiring is done
underneath the centre table, and sewing machine motor is on right side of
sewing machine table, so wiring for one column of sewing machine is
cumbersome. Material movement in this type of layout is
lateral/vertical/zigzag. Light source has to be separate for two columns of
machine, thus infrastructure cost for lighting will be more. As operators are
facing same sides (regimental seating) they are less prone to talk. The
arrangement is ‘vaastu-friendly’.
Receive garments from sewing section
Middle checking
AQL inspection
Receipt of poly packing approval
De dusting with blower
De dusting & removal of cut thread
Pressing
Presentation checking
Measurement checking
Folding
Tagging
Poly bag packing
To packing section
FINISHING SECTION
S.No. Operation SAM Pcs/min Required People
1 Thread Trimming 0.43 2.33 3.13
2 Primary Inspection/ 0.64 1.55 4.70Spotting
4 Ironing 0.64 1.56 4.67
5 Measurement Check/ 0.85 1.18 6.19Final Check
6 Final Ironing 0.96 1.05 6.97
Total 3.52 25.66
LIGHTING DIAGRAM
Definition
A light source emits a flow of energy measured by a unit of power called a
lumen. The density of light that falls on a surface is measured in foot candles,
or lux. A foot candle is one lumen of light density per square foot. A lux is one
lumen of light density per square meter. The foot candle is an older British
measurement that is largely being replaced by the metric-based lux.
Lumen: a unit of luminous flux equal to the amount of light given out through a
solid angle of 1 steradian by a point source of 1 candela intensity radiating
uniformly in all directions
Outdoor light levels, as measured by a light meter, can range from 107,527 lux
in bright sunlight to 107 lux on a very dark day. Recommended light levels (in
lux) for indoor work spaces are 500 for personal computing work; 750 for
supermarkets; 1,500 to 2,000 for detailed drawing work; and 10,000 to 20,000
for visual tasks in extremely low contrast using small-sized objects. Direct,
intense lighting is required for the latter tasks.
Activity Illumination (lux, lumen/m2)
Public areas with dark surroundings 20 – 50
Simple orientation for short visits 50 – 100
Working areas where visual tasks are
only occasionally performed 100 – 150
Warehouses, Homes, Theaters, Archives 150
Easy Office Work, Classes 250
Normal Office Work, PC Work,
Study Library, Groceries, Show Rooms, Laboratories 500
Supermarkets, Mechanical Workshops, Office Landscapes 750
Normal Drawing Work, Detailed Mechanical Workshops,
Operation Theatres 1,000
Detailed Drawing Work, Very Detailed Mechanical Works 1500 -
2000
Performance of visual tasks of low contrast
and very small size for prolonged periods of time 2000 – 5000
Performance of very prolonged and exacting visual tasks 5000 - 10000
Performance of very special visual tasks of extremely low
contrast and small size 10000 – 20000
Lux requirements in the industry:
Task Group Standard
Service
Illumination
(Lux)
Reflectance
Contrast
usually low
(Lux)
Errors will
have serious
consequence
s (Lux)
Rask of
short
duration
(Lux)
Storage area and plant room with
no continuous work
150 - - -
Casual work 200 - - -
Rough work, rough machining and
assembly
300 500 500 300
Demanding work, inspection of
medium machining
500 750 750 300
Fine work: Colour discrimination,
textile processing and fine
machining
1000 1500 1500 750
Very fine work: hand engravings,
inspection of fine machining and
assembly
1500 3000 3000 1000
Minute work, inspection of very
fine assembly
3000 3000 3000 1500
Levels specific to garment industry:
Operations Lux level
Sewing 300 - 500 for normal
1000-1500 for critical operations
Embroidery 700
Processing 150
Packing 150 – 300
Inspection 700 for routine
1000 for critical/minute inspection
COMPLIANCE REQUIREMENT:
Exemptions
75 hour O.T. Exemption
Exemption for Time Card
Exemption for Ambulance
Exemption for Creach
Building
Name Sign to All Rooms / Area
Indicators / Direction from Security Gate onwards
Storage above Storage limit Carton Box etc.
Aisle marking
Aisle width minimum 112 cm.
Indicators Arrows in the passage
Aisle without block
Health
Drinking Water
At least4.5 Litres water provided per day per employee
Water Testing Certificate
Drinking water not in plastic pot
Drinking Water, Cup availability
Drinking Water centre (one place to every 150 employees upto 500)
Drinking Water centre (one place to every 500 employees above 500)
Water Cooler / Heater available at every canteen, dining hall, rest room etc.
Drinking Water Signage in English and a local language
Locate from 20 feet away from toilet
Locate maximum 50 meters distance from work spot
Drinking Water vessels cleaned at least once in a day
Water Reservoir or Tank Cleaned at least once in a week
Water centre cleaning condition
Water Vessal Cleaning log sheet
Water Centre Incharge person with cleanliness
Suggession Box Register
Toilets
Toilet Seat to Every 20 Women
Toilet Seat to Every 20 men upto 100
Toilet Seat to Every 50 men beyond 100
All toilet seat with proper privacy and lock facility
Urinal Accommodation Min. 61 cm for every 50 employees upto first 500
Urinal Accommodation Min. 61 cm for every 100 employees for above 500
Effective water Sewage system
Soap/ Towel
Bathroom Lock
Water tap
Dust Bins
Buckets with mug at toilets
Toilet White Washed once in every four month
Tiles/Mosaic floors washed with Detergent or disinfectant once in four month
Daily Cleaning Log sheet provided
Adequate Water Tabs
No smoking Sign in Gents Toilet
Awareness Quotes in Toilets
Ladies / Gents Toilet Name Sign in Dual Language and Picture
Spittoons
Adequate Spittoons
Spittoons filled by Sand or Suitable disinfectant
Spittoons covered by bleaching powder layer
Spittoons scrapped or cleaned at least once in every day
Others
500 Cubic feet for every employees
Disposal of Wastes and effluents
Room Temperature
Lighting facility
Trees on factory campus
Safety Guards
Metal Glows on good Condition
Rubber Mat to ironers
Rubber Glows to ironers
Ironers wearing slipper
Motar Guard
Needle Guard
Eye Guard
Scissors and trimmers are tied
Broken Needle Register
Dining Hall
Dining Hall with sufficient Space
Dining Hall with Sufficient Chair/Table
Water Facility
Ambulance Room
Doctor Visit
Nurse
Medicines
Medicines Issuing Record
Creach
Fire
Sufficient Fire Extinguisher
Fire Extinguisher all in good Condition
Fire Extinguisher Location List
Fire Extinguisher Service Checklist
Fire Extinguisher kept in 3 feet
Fire Signage in English & Local Language.
Usage Guide in dual language
Fire Extinguisher Color Background Marking
Space beneath marked
Space beneath kept empty
Refilling Service Done
Fire Certified persons photo
Evacuation Drill (External) Every Six Month
Evacuation Drill (External) File
Evacuation Drill (Internal) Every Three Month
Evacuation Drill (Internal) File
Fire safety trained employees name & Photo List
Fire Buckets to Diesel Storage Area with Water and Sand
Fire Buckets to Boiler Room with Water and Sand
Fire Buckets to Generator room with Water and Sand
Diesel Storage area floor filled by sand
Evacuation Plan in all Floor / Area
Emergency Exit
Emergency Exit on Open
Emergency Exit Signage
Emergency Exit with outside open facility
Emergency Light to All room / Area Adequate
Emergency Light to All staircase
Emergency Light to All Exit & Emergency Exit
H.R.
Personnel File to All
Application Form
Passport Size Photo
Educational Qualification Certificate
Age Proof
I.D. Proof
Address Proof
Technical Certificate
Previous Company Experience/Relieving order
Old Salary Slip
ESI Nomination Form 1
PF Nomination Form 2
Gratuity Nomination Form F
Factory Act Nomination Form 34
Track Record
Appointment Order
Insurance
NDA with Signature
Employee Manual
I.d. Card to All
Adequate Swiping machine
Punching Card to All
ESI Card to All
PF Slip to All
Awareness Programme
Stress Relieve Counseling
Meetings
Performance appraisal
Leave Card
Full & Final Settlement
Exit Interview
Gratuity
Bonus
Salary Breakup
Salary on Date
Induction Programmer
Induction Register
Manpower
Manpower Department wise Male/Female Strength Report
Attendance Report
Late Report
Absentism Report
Daily Staff In-Out Register
Is there Under Age
Contract Employees
Punch report
Leave card to each employee
MIR (Material Issue Register)
Salary
Salary date before 7 every month
Bank Salary Account to all
Salary Registers with employees signature monthwise
Minimum Wages
Basic
D.A.
Other Salary Breakups
Over Time
Double Salary to Over Time
Any unwanted deduction for employee
Unpaid salary are reversed
Pay Cover Availability
Security
Adequate Securities
Lady Guards
Staff Movement Register
Visitors Note
Others In-Out Register
Material Inward Register
Material Outward Register
Vehicle Movement Register
Visitor Pass
Visitor Slip
Guards Knowledge about their Roles & Responsibilities
Securities Personnel File
Securities Uniform/Cap/Shoe/Belt etc.
Securities Knowledge about Fire Evacuation & Fire Safety
Security Agreement file (If outsourced)
Security Salary register file (If outsourced)
Security ESI, PF Challan (If Outsourced)